Strokes on appearance is getting cut off when exporting for web & Devices

I'm a screen print artist using Adobe Illustrator CS5 in windows 7(blah!) to export images of our customers' artwork into a huge folder of images on a server. The images are then loaded into a program so that they can be viewed company-wide and by the customer.
Occasionally, when there is an appearance applied to text it seems to cut off the tops and/or bottoms of the outermost stroke.This seems to be only happening to text, and happens randomly and is very annoying. See the image attached.
it does this with both JPEG and PNG images, and whats more, changes when you adjust the image size. it either gets better or worse. I have to change the image size on every export so that they are all within our size requirements.
I have found that if you put the art into an envelope with all the settings at 0 and then export for web it prevents this from happening. However, that isn't very efficient as i need to be moving a ton of artwork a day, and I am not the only person who may be working on the Illustrator file.
Is there any setting either in illustrator or windows that may be causing this anomaly?

Try adding:
Effect >> Path >> Outline Object
So  your type will still be editable
If that does not work you may want to:
Type: Create Outline
I only had this problem once before, on some snickerdoodle cookies package, and that was a script font. Might be related to the font you use.

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